Special automatic transmission (VW Passat B5)

Location of electrical connectors (A, B, C, D) and the bracket (E) securing the wiring harness to the gearbox

Torque converter mounting nut visible through starter mounting hole

Using a special clamp (1) to fix the torque converter on the input shaft of the gearbox

Warning: The operations for removing and installing the special automatic transmission are the same as those for removing and installing the manual transmission. This subsection describes the operations that apply only to the special automatic transmission.

Removal

1. Support the engine using a lifting device using the eyes attached to the cylinder head.

2. Label and disconnect the electrical connectors from the gearbox, see Fig. Location of electrical connectors (A, B, C, D) and the bracket (E) securing the wiring harness to the gearbox.

3. Unscrew the bracket securing the wiring harness to the gearbox, see Fig. Location of electrical connectors (A, B, C, D) and the bracket (E) securing the wiring harness to the gearbox.

4. Disconnect the ATF electrical connectors from the power unit and, using soft wire, tie them to the body.

5. Using a wrench, turn the crankshaft pulley mounting bolt to a position where one of the torque converter mounting nuts is accessible through the starter opening. Using a screwdriver or crowbar, secure the drive plate from turning by the teeth of the gear ring and unscrew the torque converter mounting bolt. Turn the engine crankshaft and unscrew the remaining two nuts in the same way, see Fig. The torque converter mounting nut visible through the starter mounting hole.

6. Set the selector lever to position P and, by pulling up, disconnect the gearbox control cable from the shaft.

7. Remove the bolt securing the gearshift cable housing and remove the cable.

8. Move the transmission away from the engine, supporting the torque converter.

9. Move the torque converter along the input shaft to the gearbox housing and, using clamps, fix the torque converter in this position, see Fig. Using a special clamp (1) to fix the torque converter on the input shaft of the gearbox.


10. Carefully lower the transmission and remove it from under the vehicle.

Installation

Location and tightening torques of the bolts securing the automatic transmission to the engine

Position	Bolt	Tightening torque
1	M12x75	65 Nm
2	M12x130	65 Nm
3	M12x45	45 Nm
4	M12x70	45 Nm
5	M10x60	45 Nm
6	M10x80	45 Nm
A	Guide bushings

1. Remove the clamp holding the torque converter to the transmission input shaft.

2. Using three nuts, screw the torque converter to the drive plate and tighten the nuts to a torque of 80 Nm.

3. Screw in the gearbox-to-engine mounting bolts and tighten them to the required torque, see Fig. Location and tightening torques of the automatic gearbox-to-engine mounting bolts.

4. Check that the selector lever is in position P and connect the transmission control cable to the transmission shaft.

5. Secure and, if necessary, adjust the transmission control cable.

6. Check the gearbox oil level and top it up if necessary.